Machine tool

ABSTRACT

A machine tool arranged to deliver an energy source through a processing head onto a work-piece, wherein;
         the machine-tool has a clamping mechanism arranged to temporarily receive the processing-head, or another machining or processing-head, to process a work-piece;   the processing-head comprising one or more guiding mechanisms arranged to direct the energy source onto a work-piece and a processing-head docking-manifold arranged to have connected thereto one or more media to be, in use, supplied to the processing-head to facilitate processing of the work-piece;   wherein the processing-head docking-manifold allows the one or more media to be supplied to the processing-head when the processing-head is connected to the clamping mechanism; and   wherein the machine-tool also comprises at least one mechanism arranged to move a supply docking-manifold into and/or out of connection with the processing-head docking-manifold such that when the two manifolds are connected the or each media is supplied to the processing head.

CROSS REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM

This application is a continuation of International Patent ApplicationNo. PCT/GB2013/051906 filed on Jul. 16, 2013, which claims priority toUnited Kingdom Patent Application No. 1212629.8 filed on Jul. 16, 2012and United Kingdom Patent Application No. 1307796.1 filed on Apr. 30,2013. All of these applications are hereby incorporated by reference intheir entirety.

FIELD OF THE INVENTION

This invention relates to a machine tool, or other type of machine,arranged to deliver at least one of an energy source and media through aprocessing head onto a work-piece. The machine tool may in particular,but not exclusively be referred to as a hybrid machine tool. Inparticular, but not exclusively, the invention may relate to adeposition system arranged to deposit material onto the surface of awork-piece with or without an energy source being provided in additionto the deposited material.

In addition this invention relates to a machine tool arranged to depositmaterial through a processing head onto a surface of a work piece.

BACKGROUND OF THE INVENTION

In the past machine tools have been used to remove material from a workpiece through what is termed machining and such machine tools haveincluded milling machines and the like which are often computercontrolled or Computer Numerically Controlled (CNC). As technologydevelops it is now possible to use such machines to perform otherfunctions, such as other forms of material removal (ultra-sonic, laserand the like), welding and material deposition (such as laserdeposition, hard facing, directed energy deposition, additivemanufacturing, etc.).

It is known to provide arrangements that provide processing heads thatcan be fitted to existing machine-tools, such as multi-axis CNC millingmachines. However such prior art processing-heads are not convenient asmay be desired.

It is also known in the art to use robots, such as robotic arms and thelike to process materials. It is perhaps the case that the field ofrobotic arms and machine tools are converging but it is presently thecase that they are different. For example, robotic arms are not as rigidor accurate due to the higher degree of movement and flexibility thatthey offer, which generally relegates them to second choice for heavymachining operations.

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a machinetool arranged to deliver an energy source, through a processing headonto a work-piece, wherein the machine-tool may have a clampingmechanism arranged to temporarily receive a processing-head, or anothermachining or processing-head. In some embodiments the first aspect mayrelate to a robotic arm, or the like, rather than a machine tool.

The machine tool may be arranged to process a work-piece.

Typically the clamping mechanism is housed in the nose of the spindle.Further, the machine tool typically has an axis passing through theprocessing head when connected to the clamping mechanism and about whichthe processing-head is arranged to move.

The processing-head may comprise one or more guiding mechanisms arrangedto direct the energy source onto a work-piece.

The processing head may also comprise a docking-manifold arranged tohave connected thereto one or more media to be, in use, supplied to theprocessing-head to facilitate processing of the work-piece.

The docking-manifold may allow the one or more media to be supplied tothe processing-head when the processing-head is connected to theclamping mechanism.

Conveniently, the machine-tool also comprises at least one mechanismarranged to move a supply docking-manifold into and/or out of connectionwith the processing-head docking-manifold such that when the twomanifolds are connected the, or each, media is supplied to theprocessing head.

The supply docking-manifold may be arranged to allow the energy sourceto be transmitted into the processing-head.

Generally embodiments allow the energy source to be transmitted throughthe processing-head docking-manifold once the two manifolds areconnected. Such embodiments are convenient in that they allow the energysource to be connected as the manifolds are brought together.

In other embodiments, the energy source may be transmitted along an axisof the machine tool. The axis may be aligned through an axis of theclamping-mechanism. The skilled person may understand this as beingalong an axis of the spindle of the machine tool and may include guidingit through a hollow spindle.

Embodiments may have ducts within the docking-manifold arranged tosupply at least one of a cooling-medium arranged to cool the or eachguiding mechanism within the processing-head, a processable mediumarranged to be processed, in use, by the energy source and a shieldingmedium. Conveniently, each of cooling, shielding and processable mediamay simply be referred to as media. Again, such embodiments areconvenient since they allow the, or each, media to be convenientlysupplied, in use, once the manifolds are connected.

It will be appreciated by those skilled in the art that it is desirableto provide an inert environment when exposing selected materials toenergy and/or temperature. This can be done via delivery of shieldinggas (ie a shielding medium) locally such as through the processing head.Alternatively, this activity can be undertaken inside a chamber providedaround the machine tool, or at least a part of the machine tool, whichmaintains a vacuum or alternative inert environment.

Many embodiments provide an alignment mechanism arranged to align atleast one of the medium supplies and the energy source with the ductswithin the processing-head docking manifold. It will be appreciated thatenergy sources often need to accurately aligned in order that they arefocussed, in use, correctly and providing an alignment mechanism ensuresthat an energy source that is connected as the two manifolds connect iscorrectly aligned.

In some embodiments, the alignment mechanism is provided, at least inpart, by a substantially planar surface.

Conveniently, there is a housing connected to the supplydocking-manifold. The housing may contain guiding mechanisms for theenergy source. In one embodiment, the housing contains a beam expanderarranged to expand a laser beam. Providing at least some of the guidingmechanism external of the processing head can help to ensure that theyare provided with a less harsh environment when compared with theenvironment within the processing head. The skilled person willappreciate that some guiding mechanisms are relatively fragile.

Typically, embodiments are arranged, in use, to focus the energy sourceonto a region in line with a longitudinal axis of the processing head.Such an arrangement is convenient in that it can make the machine-tooleasier to program, since there is no need to take account of offset inmultiple axes, and smaller since the working area does not need toaccount for an offset. The skilled person will understand that as thefocus of the energy source is offset from the axis then the working arearequired to process an object increases significantly since furthertranslations are required to account for the offset.

Embodiments may provide the energy source as at least one of thefollowing: laser, electron beam, arc, plasma, microwaves, masers,focused electromagnetic radiation, or sound waves (includingultrasound), or the like. The electromagnetic radiation may for examplebe any of the following: x-rays, microwaves, ultraviolet light, infraredradiation, or the like.

The guiding mechanism provided within the processing head and/or withinthe housing may comprise any of the following: one or more lenses,mirrors, prisms, diffraction gratings, beam expanders, spatial lightmodulators, optics, electrical coupling mechanism, conductive mediapaths, induction coupling mechanism, beam steering components, beamsteering field generators, micro-electromechanical systems, micro-mirrordevices, shielding components such as Electro Magnetic Interference(EMI) shielding including co-axial cable, or the like. However, it isconvenient if the processing-head comprises more robust and fewercomponents.

In particular, the processing-head, in some embodiments, may comprise alens and a reflector.

The machine tool may, in use, be arranged to supply at least one of thefollowing: a metal, polymer, or ceramic material typically in powder orfilament form; cooling or processing fluids; gases; processing fluid, orthe like.

Conveniently, a controller of the machine-tool is arranged to cause themachine-tool to change the processing-head within the clamping mechanismautomatically, or at least semi-automatically. The skilled person willappreciate that the term controller of the machine tool is arranged tocover both controllers internal of the machine tool and those networkedor otherwise coupled to the machine tool.

It will be appreciated that the term “machine tool” has been used inrelation to the machine as a whole. Interchangeable heads have beendescribed and conventional milling and machining heads, sometimesreferred to as machining cutters or tools, have been referred to amachining heads. As disclosed in this application alternative heads,termed “processing heads” are used to process a work piece which mayinvolve the direction of energy to a work piece or the direction ofmedia and energy to a work piece or the application/deposition of mediaon a work piece.

The skilled man will appreciate that although the invention has beendescribed in relation to a machine tool it is envisaged that it would bepossible to modify robots or other additive manufacturing equipment touse tool changes and/or docking stations. Such modified equipment may beconsidered to be similar to machine tools once they have been somodified.

According to a second aspect of the invention there is provided a kitcomprising a processing-head in combination with a supplydocking-manifold wherein the processing-head is arranged, in use, to beconnected to a clamping mechanism of a machine tool, or the like, andfurther comprises at least some of the following:

-   -   a) one or more guiding mechanisms arranged to focus an energy        source onto a work-piece;    -   b) a processing-head docking-manifold arranged to have connected        thereto one or more media, in use, to be supplied to the        processing-head to facilitate processing of the work-piece; and    -   c) the supply docking-manifold comprises a mechanism arranged to        move the supply docking-manifold into and/or out of connection        with the processing-head docking-manifold such that when the two        manifolds are connected media is, in use, supplied to the        processing head.

Embodiments may arrange the docking-manifold to allow an energy sourceto be transmitted into the processing-head. Conveniently, a housing isconnected to the supply docking-manifold.

Embodiments may typically provide the processing-head docking-manifoldwith ducts therein arranged to supply at least one of a cooling-mediumarranged to cool the or each guiding mechanism within theprocessing-head and an energy source processable medium arranged to beprocessed, in use, by the energy source. Other fluids and/or media asdescribed herein may also be communicated between the two manifolds.

In some embodiments, further guiding mechanisms may be provided inaddition to the guiding mechanism within the processing-head, which maybe associated with the supply docking-manifold.

At least some embodiments of the invention may arrange at least one ofthe guiding mechanism (the guiding mechanism within the processing-headand/or the guiding mechanism therein addition to) such that the energysource processable medium can be selectively melted within theprocessing head or externally of the processing head.

In alternative, or additional embodiments, the kit may comprise aplurality of processing heads each of which is arranged to focus theenergy source differently to other processing-heads within the kit. Forexample, a first processing-head may be arranged to melt the energysource processable medium within the processing head. A secondprocessing head may be arrange to melt the energy source processablemedium external to the processing head.

Conveniently the docking-manifold comprises an alignment mechanismarranged to align medium supplies within the supply docking-manifoldwith ducts within the processing-head docking manifold. In someembodiments a docking arm may be provided which is arranged to connectthe head to the clamping mechanism. The arm may then be retracted to astorage location.

In some embodiments there may be multiple docking arms. In addition oralternatively there may be provided multiple tool changers.

Typically, the alignment mechanism is arranged to have, in use,connected thereto a housing arranged to transmit the energy source intothe processing-head.

The housing may be arranged to contain the further guiding mechanism inaddition to the guiding mechanism contained within the processing-head.

Embodiments will typically be arranged to focus the energy source on toa point or area in line with a longitudinal axis of the processing head.

According to a third aspect of the invention there is provided a methodof connecting a processing-head arranged to focus an energy source ontoa work-piece, the method comprising:

-   -   a) causing a machine tool, or the like, to select the        processing-head from a storage location and insert the        processing-head into a clamping mechanism of the machine-tool;        and    -   b) activate a mechanism arranged to move a supply        docking-manifold into connection with a processing-head docking        manifold;    -   c) wherein connection of the supply docking-manifold and the        processing-head docking-manifold provides a supply of one or        more medium supplies to the processing-head such that, in use,        the or each medium can be supplied.

The method may additionally comprise the process in reverse to replacethe processing head within a storage area of the machine tool.

According to a fourth aspect of the invention there is provided a methodof repairing a part comprising at least one of the following steps:

-   -   a) causing a machine-tool to select a processing-head    -   b) causing the machine tool to connect a supply of media to the        processing head;    -   c) causing the machine tool to perform an additive processing        step in which material is added to the part;    -   d) causing the machine tool to replace the processing head        within a storage area;    -   e) causing the machine tool to select a machining head from the        storage area;    -   f) causing the machine tool to remove material from at least the        material that has been added to the part being repaired; and    -   g) optionally select an alternative machining, processing or        inspection head (such as a touch probe) and inspect or treat the        work piece.

The processing head may be the processing head of any of the aboveaspects of the invention.

The method of paragraphs a and b may be the method of the third aspectof the invention.

In some embodiments there may also be provided connections forelectrical, optical and mechanical connections between the processinghead and the machine tool. Such connections provide connections forprocess monitoring sensors and equipment. Such sensors may compriseimage recording apparatus, lighting, touch probes, 3D surface andvolumetric scanners, sensors such as oxygen sensors and thermal sensorsor cameras and the like. In some embodiments the temperature sensor maybe used to monitor a temperature of the work piece on which processingis being carried out. The process monitoring sensors or measuringequipment may comprise part of the processing head, part of a manifoldarranged to have connected thereto one or more media and/or be inaddition to both the processing head and the manifold. For example, someembodiments may provide process monitoring sensors as a separate head,which may be thought of as an inspection head, in addition to anyprocessing heads and machining heads.

In some embodiments the temperature of one or more melt pools may bemonitored. A melt pool may be formed where material is deposited. Themedia may be applied to or toward the work piece and melted by theapplication of energy from an energy source. Thus, the media may bethought of as being an energy source processable medium.

In additional, or alternative, embodiments, the media may be depositedin a molten state.

According to another aspect of the invention there is provided a multiaxis machine tool, the machine tool may have at least one processinghead and conveniently at least one machining head. The machine tool mayhave a clamping mechanism arranged to temporarily receive one of the atleast one processing head and/or the at least one machining head,wherein the machine tool may be operable, in use, to perform at leastsome of the following five steps i) to move the processing head ormachining head from an operable position to a head changing position,ii) release the processing head or machining head from the clamping orholding mechanism, iii) select an alternative processing head ormachining head; iv) receive the alternative processing head in theclamping or holding mechanism, and v) return to the operable position,

-   -   the processing head may be further arranged to deposit material        onto a work piece being processed and wherein;    -   the processing head typically comprises a media supply.

In an embodiment of the invention an energy source may be provided inthe processing head. Alternatively an energy source may be generatedexternally of the processing head and the processing head may bearranged to direct the or otherwise convey the energy source. In someembodiments the energy source is provided by a battery, or otherisolated energy source, such as fuel cell or the like. In anotheradditional or alternative embodiment the energy may be generated in thehead by the motion of the spindle, such as via a generator, alternatoror the like. In other embodiments the energy source is supplied to theprocessing head.

The machine tool may be arranged to process a work-piece. Alternatively,or in addition the machine tool may be arranged to deposit the materialon a work piece or to build a work piece, which may be building the workpiece up from scratch. Such an operation may be additive depositionincluding additive manufacturing, 3D printing, or digital fabrication,or the like. Preferably the machine tool also comprises a tool changerarranged to change a head in the machine tool. The tool changer mayexchange a processing head for a machining head or vice versa.Alternatively the machine tool may be provided with two or moreprocessing heads. The tool changer may comprise a storage area locatedoff set from the work piece.

Typically the clamping mechanism is housed in the nose of a spindle.Further, the machine tool typically has an axis passing through theprocessing head when connected to the clamping mechanism and about whichthe processing-head is arranged to move.

The processing-head may comprise one or more guiding mechanisms arrangedto direct the energy source onto a work-piece. In another embodiment theprocessing head may comprise one or more guiding mechanisms arranged todirect energy from the energy source into the media and/or to amechanism for depositing the media. The energy may be applied to themedia in the processing head or externally of the processing head suchas on the surface of the work piece, or at least as the media movestoward a work piece.

The processing head may comprise, as before, a docking manifold arrangedto have connected thereto one or more media that are in use supplied tothe processing head to facilitate processing of the work piece. Theenergy source may be supplied to the media inside the processing head ormay as previously described be supplied to the media as it travelstoward and/or arrives on the work piece. In one alternative the energyis supplied to the media in the processing head and the media isdeposited on the work piece. The energy may be supplied to the mediaprior to leaving the processing head or may be supplied to the media asthe media leaves the processing head.

The processing head may comprise a media supply arranged to supply mediato the head from the machine tool, from the clamping mechanism, or froman ancillary piece of equipment connected or convenient to the machinetool. In yet another embodiment the media supply may comprise a mediareservoir provided in the processing head. In some embodiments the mediareservoir may be continuously refilled via a supply which feeds mediathrough a manifold. In other embodiments the media may be provided inthe form of a replaceable cartridge forming a media supply. In yetanother embodiment the media reservoir may be refillable while theprocessing head is located in the tool changer. A supply manifold may beprovided in the tool changer and may be arranged to connect to theprocessing head in the tool changer and to automatically refill themedia reservoir. Additionally or alternatively at least one mechanismmay be provided to move the supply manifold into and out of connectionwith a media supply when the processing head is in an operative positionon the machine tool or when the processing head is located in the toolchanger or another storage location.

In some embodiments one media is supplied to the processing head. Inother embodiments two or more media may be supplied to the processinghead. The media may for example comprise alternative colours oralternative media. In some embodiments a first media may comprise abuilding material and a second media may comprise a support material.The support material may be removable once the work piece is completed.Should a plurality of media be provided then the tool may be arranged tobe able to selectively use those media.

In some embodiments the media may comprise a polymer material. In otherembodiments the media may be selected from a group comprising metals,non-metals, polymers, ceramics, clay or dielectric materials. The mediamay be provided in any of the following forms: in powder form;filaments, rods, or wires, in semi- to fully liquid form. Alternativelymedia can be provided as, or in suspension in, a liquid, emulsion, gas,aerosol, slurry or paste.

In one particular embodiment the media may comprise a polymer filament.Typically such a filament may be heated by the energy source to atemperature such that the media can be fed, directed, extruded, jettedor otherwise deposited in a controllable manner. Alternatively a fluidmedia may be supplied to the processing head from the media reservoir.The media may be heated by the energy source till all the media in thereservoir is fluid and can be dispensed, or otherwise expelled, in acontrollable manner. In some embodiments the media may also compriseconductive, semi-conductive, and dielectric material such that electriccircuits can be laid down during formation of the workpiece. In analternative embodiment the media may pass from the reservoir towards adeposition tip of the processing head and the energy may be applied tothe media prior to the media leaving the deposition tip. This may beparticularly suitable for embodiments in which the media is in the formof a filament or wire and the media can be fed through the processinghead by mechanical feeding mechanism such as by rollers. It may bedesirable for the media to be relatively stiff until the media is aboutto be deposited. The energy may be applied just before the media leavesthe deposition tip or as or after the media leaves the deposition tip.Alternatively, or additionally, the material may be deposited onto thesurface of the work piece and then exposed to the energy.

A media feed may be provided connected to the tool changer. The mediafeed may supply media to the processing head or to a reservoir in aprocessing head when the processing head is not in use. The feed may bepart of an additional docking mechanism which engages with theprocessing head or machining head when it is not in use.

According to another aspect of the invention there is provided a kitcomprising at least one of a processing head; a media reservoir; a mediasupply; and an energy source.

In one embodiment there is provided a kit comprising a processing headin combination with a media reservoir wherein the processing head isarranged in use to be connected to a clamping mechanism of a machinetool and wherein the media reservoir is provided in the processing head.

In another embodiment of the invention there is provided a processinghead adapted to be connectable to a machine tool according to an aspectof the invention wherein the processing head is suitable for depositingmaterial onto a work piece and wherein the processing head furthercomprises a media supply preferably in the form of a reservoir.

In a preferred embodiment the processing head further comprises anenergy source, or at least a mechanism for generating an energy source,arranged to supply energy to the media and/or to a mechanism fordepositing the media.

In an alternative embodiment the kit comprises a processing headarranged to be connectable to a media supply. The media supply maycomprise a media feed or manifold connected to the tool changer andarranged to replenish the media reservoir when the processing head islocated in the tool changer or may be provided connected to the machinetool and arranged to supply the media to the processing head when theprocessing head is on the spindle or other usable position.

In some embodiments the media feed may comprise one or more channels andwherein the media feed may feed the media to the work piece or thechannels may be arranged to provide reverse flow of the media or maydivert or re-circulate the media. In some embodiments there may be amechanism provided to recapture unused media or to remove waste media orby-products or outgassing. Such a mechanism may be provided in additionto the flow of media in the or each of the channels.

In some embodiments a mechanism to provide the energy source is selfcontained in the processing head. In other embodiments the energy sourceis connected to the processing head. The energy source may comprise forexample UV, IR, laser or other energy sources as described previouslyand may in some embodiments direct a beam of energy onto the work piece.

The kit may comprise in alternative or additional embodiments aplurality of processing heads having alternative media suppliescontained therein. In a further alternative a processing head maycomprise a replaceable cartridge containing a media supply. Thecartridge may be automatically replaceable or may be manuallyreplaceable.

In some embodiments the kit may further contain a docking manifoldarranged to supply a media to the processing head. The docking manifoldmay comprise one or more ducts within the manifold arranged to supply atleast one source of media to the processing head.

Alternatively the kit may comprise a media supply mechanism arranged tosupply a media to the processing head. The media supply mechanism may bearrangeable to supply media to the processing head when the processinghead is in an operable position on a spindle of the machine tool oralternatively the media supply mechanism may be arranged to supply mediato the processing head when the processing head is located in the toolchanger.

According to another aspect of the invention there is provided a methodof forming a work piece comprising

-   -   a) causing a machine tool to select a processing head from a        storage location to insert the processing head into a clamping        mechanism of the machine tool; and    -   b) activating a mechanism arranged to supply energy to a media        in the processing head and/or to a mechanism for depositing the        media;    -   c) controlling deposition of the media from the processing head        so as to construct a work piece.

In some embodiments of the method a further step may be carried out inwhich heat or other energy from the deposition or consolidation of mediaon the work piece, is also used to heat a surface of the work piece. Inaddition or alternatively heat from the deposition may be used to cure,melt, sinter, crosslink, react or otherwise catalyse change in thedeposited material. For example, inks or pastes for directly printingelectronics may require heating to achieve their designed conductivity,resistivity or other properties; may derive secondary benefit from theheat of deposition operations, rather than requiring additional heatingsteps. Where secondary benefits cannot be leveraged for materialtreatment, an explicit processing step can be made as described below.

According to a further aspect of the invention there is provided amaterial processing system comprising a material processor, which may bea machine tool or a robotic arm or the like, having a processing headwhich the material processing system is arranged to move relative to awork piece and a controller arranged to control the movement of theprocessing head; typically, the processing head will comprise one ormore guiding mechanisms arranged to direct an energy source on the workpiece under the control of the controller, where the controller cantypically control the amount of power delivered to a given area of thework piece.

Here power is intended to have its correct meaning of total energyaccumulated over time. Thus, it will be appreciated that in order tocontrol the power it is possible to control the rate at which energy issupplied (ie the power thereof) or to control the rate which the energysource is moved across the work-piece.

Such embodiments are convenient as they can control the effect that theenergy source has on the work piece. The skilled person will appreciatethat the power that is delivered can significantly effect what happensto the work piece.

The controller may be arranged to use the movement of the processinghead to control the amount of power. The skilled person will appreciatethat if the processing head is moved at a relatively higher speed acrossthe work piece that less power will be provided to the work piece thanif the processing head is moved at a relatively lower speed.

The energy source may be any of the sources described in relation to theabove aspects of the invention.

Thus, in some embodiments, the guiding mechanism may comprise at leastone lens arranged to focus the energy source on to the work piece. Theguiding mechanism may comprise any of the guiding mechanisms mentionedelsewhere.

As with the aspects described above, embodiments of the invention may beprovided with a mechanism to generate the energy sources internally ofthe processing head. Additional, or alternative, embodiments may bearranged to direct an energy source which is generated externally of thehead.

The processing head may comprise a mechanism to selectively activate ordeactivate the energy source. For example, the controller may bearranged to selectively activate and/or deactivate generation of anenergy source. Thus, in the example of a laser beam, the controller maybe arranged to activate and/or deactivate the generation of the laserbeam or alternatively the controller may be arranged to control thefocusing or de-focusing of the laser beam, or the like.

The controller may be provided by a processing circuitry external to thematerial processor, wherein the material processor is one of a machinetool and a robotic arm or the like. For example, the processingcircuitry may be provided by a computer external to but connected to thematerial processor. In other embodiments the controller may be providedby a processing circuitry within the material processor.

The material processor may be arranged to change the material propertiesof the work piece. For example, the material processor may be arrangedto control the power such that the, or a least a portion of, the workpiece is heated, pre-heated, hardened, softened, deliberately stressed,stress-relieved, or porosity/void-related defects reduced/closed. Theseoperations may be undertaken to avoid cracking, warping, and otherdefects. Alternatively, the surface of the work piece may be modifiedsuch as by marking, texture patterning, texture enhancement, selectiveoxidation, or have its surface roughness reduced through re-melting,ablation, etc. Alternatively the grain structure or chemistry could bemodified such as converting steel grains to be martensitic or inducinglocal alloying with an additional material or carburizing.

The material processing system may also comprise a fluid supply, whichwould typically be under the control of the controller. The controllermay be arranged to control the supply of fluid from the fluid supply toquench, clean, shot peen, sand blast or treat the, or at least theportion of, the work piece which is being processed.

Alternatively, or additionally, the controller may be arranged tocontrol the supply of fluid to provide an inert or element rich (as incarburizing) environment, to quench, to lubricate, or the like the, orat least a portion, of the work piece. Such fluids, gases and liquidsmay also be thought of as media.

There may be more than one fluid supply wherein each fluid supply may bearranged to supply a different fluid.

The fluid supplied by the or each fluid supply may be any one of thefollowing: water; oil; an inert gas such as a noble gas; air, machinecoolant, etchant, cleaning fluid, patina, colorant, or the like.

In other embodiments, the controller may be arranged to control theenergy source processing the work piece. Here processing of the workpiece is intended to cover at least the following: stressing; stressrelieving; microstructure modification; chemistry modification; porosityreduction/elimination; welding; brazing; joining; cutting; drilling;milling; marking; plasma spraying; thermal spraying; surface re-melting;heat treating; or the like.

In some embodiments, the material processing system may comprise asupply of media. The supply of media may be as described in relation toany of the above aspects of the invention. Thus, in some embodiments,the supply of media may be delivered into the processing head via amanifold. In other embodiments, the supply of media may be providedwithin the processing head conveniently by a cartridge or the like.

In some embodiments the material processing system may be arranged tosupply media to a work piece that has previously been heated by theenergy source. In such embodiments, the media may comprise a powder, orthe like. Such powders, and similar materials, may be arranged to melt,sinter, and/or chemically react on the work piece due to, or at leastaccelerated by, the power previously applied to the work piece by theprocessing head.

According to a further aspect of the invention there is provided amethod of processing a work piece by controlling the power delivered tothe work piece by guiding an energy source relative to the work piece,under the control of a controller, such that a material property of thework piece is changed.

The skilled person will also appreciate that aspects of the inventionmay comprise software, firmware, or hardware elements arranged toprovide control of the machine tools described herein.

Manufacturing a work piece using a combination of an additive process,including deposition, and a subtractive process, including milling, asrequired is a form of hybrid manufacturing as known in the art; thechange over between these (and other operations, such as probing) ismade convenient by embodiments and aspects described herein.

The skilled person will appreciate the above aspects of the inventionintroduce various features and will further appreciate that the featuresfrom one aspect of the invention are applicable, mutatis mutandis, toother aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

There now follows, by way of example only, a detailed description of anembodiment of the invention of which:

FIG. 1 shows a machine tool;

FIG. 2 schematically shows a section through parts of an embodiment ofthe invention;

FIG. 3 shows further detail of a manifold used in an embodiment of theinvention;

FIG. 4 a shows an embodiment of the invention in an unassembled manner;

FIG. 4 b shows the embodiment of FIG. 4 a in a partially assembledmanner;

FIG. 4 c shows the embodiment of FIGS. 4 a and 4 b in a fully assembledmanner;

FIG. 5 shows a view of an embodiment of the invention from a firstangle;

FIG. 6 shows a view of the embodiment of FIG. 5 from a second angle;

FIG. 7 shows a view of the embodiment of FIG. 5 from a third anglehighlighting a transport mechanism;

FIG. 8 shows a perspective view of the embodiment of FIG. 5 illustratingmedia supplies thereof;

FIG. 9 outlines a flow-chart illustrating a method of using theembodiment described in relation to FIGS. 1 to 5;

FIG. 10 shows an example work-piece that has been processed by amachine-tool according to an embodiment of the invention;

FIG. 11 shows a schematic illustration of an alternative processing headin accordance with another aspect of the invention, and

FIG. 12 is an illustration of a further alternative processing head;

FIG. 13 is a schematic drawing of an embodiment for applying a heatedpolymer;

FIG. 14 is a schematic drawing of an embodiment for applying a liquidmedia to a work piece;

FIG. 15 is a schematic drawing of an embodiment for applying a heatedpolymer;

FIG. 16 shows a further embodiment using a plasma transferred arc basedenergy source;

FIG. 17 a shows the embodiment of FIG. 16 in an unassembled manner;

FIG. 17 b shows the embodiment of FIG. 17 a in a partially assembledmanner;

FIG. 17 c shows the embodiment of FIGS. 17 a and 17 b in a fullyassembled manner; and

FIG. 18 shows a further embodiment in which a processing head isarranged to deliver a source of energy onto a work piece.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows, schematically, a machine-tool 100, which typicallycomprises a machining head 102 held in a clamping mechanism of themachine-tool 100 and arranged to machine a work-piece 104. Further, themachine-tool 100 is usually controlled by a controller 106 whichcontrols the position of the machining-head 102 as it processes thework-piece 104.

Most machine-tools 100 are arranged such that the machining-head 102 canbe interchanged with other machining-heads 102 in order that the correctmachining-head 102 is provided for the task at hand. Providing theexample of milling machine, then a first machining-head may be providedfor coarse material removal, whereas a second machining-head may beprovided for fine material removal.

As such, machine-tools 100 have tool-changers which can, typically underthe control of the controller 106, change the machining head 102 beingused by the machine-tool 100 to process the work-piece 104.

FIG. 2 illustrates a processing-head 200 which connects to themachine-tool 100 using the clamping mechanism 202 of the machine-tool100 and which can be stored in a store of machining-heads andautomatically connected to the machine-tool 100 with a tool-changerthereof. Here the tool-changer may provide a storage-location forprocessing-heads, machining-heads, etc. which are not currently beingused by the machine-tool. Discussion herein refers to aclamping-mechanism 202 and it is assumed that a spindle into which theclamping mechanism 202 connects is part of the machine-tool 100.

In the embodiment being described, the processing head 200 is arrangedto focus a laser beam 206 onto the work-piece 104. In other embodiments,other energy sources may be utilised instead of the laser. Thus, theprocessing head is arranged, under the control of the controller 106, toprocess the work-piece 104 with the focussed laser beam 206 (or otherenergy source).

In FIG. 2, a section is shown through the processing-head 200 and it canbe seen that a reflector, such as a mirror 208, arranged to move anincoming laser beam 210 through ninety degrees to be incident upon afocussing-lens 212 for creation of the focussed-laser beam 206. Thefocusing-lens 212 may be thought of as being a guiding-mechanism. Itwill be appreciated that other processing heads 200 may have otherarrangements of the optical parts such as the reflector and focussinglens, or indeed may have additional optical parts.

In addition to the laser beam and optical components, theprocessing-head 200 also contains one or more ducts to deliver a media.For the example, the media may comprise a polymer and/or metallic powderwithin a transport fluid which is arranged to be melted by the energysource. The processing is arranged such that media is delivered throughthe processing-head and it passed into the energy source such that it ismolten or at least semi-molten before the media reaches the work-piece104. As such, the processing-head can be used to deposit material ontothe work-piece and provide a deposition system, which may for example beused to repair parts.

The machine tool (including a spindle) and the clamping-mechanism 202have a longitudinal axis, represented by the dashed line XX in FIG. 2.Should a machining-head (such as a milling cutter) be present within theclamping-mechanism 202 then it would rotate about the axis XX.Conveniently, the energy source, which in the embodiment being describedis the laser-beam 206, is focused onto a point, area, etc. 213 that liessubstantially upon the axis XX on the surface of the work-piece 106.

In other embodiments, the focusing-lens 212 may in fact be arranged tocause a divergent beam, such as would be the case for pre-heating thesubstrate, heat treating the work piece or in some types of thermalspraying and the like.

Although not shown in the drawings, some embodiments of the inventionmay be arranged to transmit an energy source through a spindle of themachine tool along the axis XX; ie from the region of point 207 shown inFIG. 2. In such embodiments the supply-unit would supply media to theprocessing head 200.

Adjacent to the processing head 200 and clamping-mechanism 202 there isprovided a supply-unit 214 which provides a housing in which variouscomponents are housed. The processing-head 200 comprises aprocessing-head docking-manifold 201 and the supply-unit 214 comprises asupply docking-manifold 300, described hereinafter, which are arrangedto mate with one another to connect the supply-unit 214 to theprocessing-head 200 in the condition as shown in FIG. 2.

On top of the supply-unit 214 there is provided an energy source 216,which in the embodiment being described is a laser. The laser 216generates a beam which is transmitted into the supply-unit 214 andpasses through a beam expander 217 comprising a first and a second lens218, 220 respectively. The beam expander 217 is utilised to increase thediameter of the laser beam in order to achieve a better final focus ontothe work-piece 104 and reduce the thermal load on the optics.

The supply-unit 214 also comprises a further reflector 222 arranged toreflect the beam of light from the laser through 90° toward theprocessing head 200 and the reflector 208 therewithin. Each of thelenses 218, 220 and reflector 222 may be thought of as being guidingmechanism provided within the supply-unit 214.

The supply-unit 214 also comprises a supply of various media 224 whichconnects through the manifold to the processing-head 200 when thesupply-unit 214 is connected thereto.

The skilled person will appreciate that the area 226 around thework-piece 104 is typically referred to as the working area (or volume)of the machine-tool.

FIG. 3 shows the supply docking-manifold 300 of the supply-unit 214 ofan embodiment of the invention. Central to the supply docking-manifold300 is a duct 302 arranged to allow the energy source, which in theembodiments described herein is a laser, to pass between the supply-unit214 and the processing-head 200.

Also visible on the supply docking-manifold 300 are ducts 304, 306, 308,310 which are arranged to deliver cooling medium, a shielding gas andmaterial to be processed by the processing-head 200 from the supply-unit214 to the processing-head 200. Typically a seal will be provided on atleast one of the manifold on the supply-unit 214 and the manifold on theprocessing head 200 in order that the ducts 304-310 are sealed and toprevent the escape of the media passing therethrough.

As the skilled person will appreciate the shielding gas will typicallybe an inert gas such as argon or the like arranged to prevent chemicalreactions, such as oxidation, etc, from occurring on the work-piece 104as it is being processed.

In some embodiments, the beam expander 217 may be arranged such that itmay be adjusted in order to vary the focal point of the final focus.Such an arrangement may help to determine whether material to beprocessed is melted by the energy source within the processing-head orafter the processing-head. The skilled person will appreciate thatvarying the point at which the processable material melts can determinethe bonding, finish and residual stress on the work-piece beingprocessed.

In one embodiment, the mating surfaces of the two manifolds (ie face 312on the supply docking-manifold 300 and the corresponding face on theprocessing-head docking-manifold) are substantially planar so that, asdescribed hereinafter, the supply-unit 214 can be docked when away fromthe processing head 200 in a manner to prevent the ingress of dirt intothe duct 302 in particular. Thus, the substantially planar surface maybe thought of as a flat surface and may be thought of as providing analignment mechanism.

Also provided on the supply docking-manifold 300 are provided locatingmechanisms (in this case locating pins 314, 316) arranged to engage withcomplementary features on the processing-head docking-manifold. Theskilled person will appreciate the pins 314, 316 be provided on theprocessing-head docking-manifold and recesses on the supplydocking-manifold 300 or one or more pins may be provided on eachmanifold. Indeed locating mechanisms other than locating pins may beused. The locating mechanisms, in addition to the substantially planarsurfaces, may be thought of as being an alignment mechanism.

FIG. 4 shows the supply-unit 214, the processing head 200 and theclamping mechanism 202 arranged in various conditions relative to oneanother as is now described.

In FIG. 4 a, shows an undocked condition, in which the supply-unit 214is in a first condition, which may be thought of as a storage condition.The supply docking-manifold 300 thereon is positioned against asubstantially planar docking surface 400 in order that the ducts 302-310are closed. The processing head 200 is stored away from theclamping-mechanism 202. Often the processing head 200 will be stored ina tool-changer of the machine-tool 100 but this need not be the case.

FIG. 4 b shows the system in a condition in which the processing-head200 has been positioned within the clamping mechanism 202 whilst thesupply-unit 214 remains in the first condition as shown in FIG. 4 a. Theprocessing head 200 will typically be selected and inserted into theclamping mechanism 202 using the machining head changing routine. Theskilled person will appreciate that in many embodiments this changingroutine is automatic, or at least semi-automatic, and is often under thecontrol of the controller 106.

FIG. 4 c shows the system in a docked condition, in which thesupply-unit 214 is in a second condition with the supplydocking-manifold 300 docked against the processing-head. In the dockedcondition, the ducts 302-310 in the supply docking-manifold 300 alignwith co-operating ducts within the processing-head 200.

In some embodiments, an air blast system is associated with the supplydocking-manifold 300 such that as the supply docking-manifold 300 isdisconnected from the processing-head docking-manifold a blast of air(or indeed any other suitable fluid) passes over or through the ducts302-310 to help try and prevent contamination from entering those ducts.

The skilled person will appreciate the three stages in FIGS. 4 a to 4 coutline connecting the processing-head 200 to the clamping-mechanism 202before the supply-unit 214 is connected to the processing-head 200. Inother embodiments, the order of connection may be different and forinstance it is conceivable that supply-unit 214 could be connected tothe processing-head 200 before the processing-head 200 is engaged intothe clamping-mechanism 202.

FIG. 5 shows a further embodiment although like parts are referred tothe same reference numerals. FIG. 5 illustrates mechanisms that are usedto move the supply-unit from the first, undocked, condition (as shown inFIG. 4 a) to the second, docked, condition (as shown in FIG. 4 c).

FIG. 6 shows a further elevation of the embodiment of FIG. 5 lookingonto the supply docking-manifold 300; ie looking at FIG. 5 from theright hand side.

A first movement mechanism is provided to move the supply-unit 214 in avertical manner and the embodiment being described this comprises a rack500 provided along a portion of the outer surface of the supply-unit214. The skilled person will appreciate that although the Figureillustrates the rack on a side of the supply-unit 214 is could beprovided at any location around the circumference of the supply-unit 214and there may in fact be more than one such rack. Indeed, as can be seenfrom FIG. 7 the embodiment being described comprises two racks 500 a,500 b on the side of the supply-unit 214.

FIG. 7 also more clearly shows the pinion mechanism 700 mounted on aframe 502. As the pinion mechanism 700 is activated then gears thereininteract with the rack 500 a, 500 b and move the supply-unit 214 in upor down depending on the direction in which the gears are driven.

It will also be noted from FIG. 7, that in the embodiment beingdescribed the housings of the pinion mechanism 700 engage with the racks500 a, 500 b in order to act as a guide for the supply-unit 214. Inother embodiments, other guide mechanisms may be provided.

A second movement mechanism is provided to move the supply-unit 214 in ahorizontal direction. In the embodiment being described, the secondmovement mechanism comprises two worm gears 504,506 provided, one towardthe top and one toward the bottom of the frame 502.

It will be appreciated that each of the first and second movementmechanisms provide at least one mechanism arranged to move the supplydocking-manifold 300 into and/or out of connection with theprocessing-head docking-manifold such that when the two manifolds areconnected the or each media is supplied to the processing head; ie theducts 302 to 310 within each of the manifolds are connected to oneanother.

A driven gear is provided within a housing 702 adjacent the pinionmechanism 700 and arranged to drive the supply-unit 214 relative to theworm gear 504, 506 thereby moving the supply-unit 214 in a horizontaldirection.

In other embodiments, the first and second movement mechanisms may beprovided by mechanisms other than gears. For example, pneumatic and/orhydraulic actuators may be utilised. Whilst in the embodiment beingdescribed there are two movement mechanisms, the skilled person willappreciate that in other embodiments there may be fewer, or more,movement mechanisms.

FIG. 8 shows the supply docking-manifold 300 of the embodiment of FIG. 5in more detail. It can be seen that in this embodiment the ducts 304-310comprise connectors at end regions thereof and arranged to connect withcomplementary connectors within the processing-head docking manifold.

In summary of the above, and with reference to FIG. 9, in order tochange the processing head on the machine-tool 100 the machine-toolscontroller 106 instigates its tool changing routine and picks up theprocessing head 200 (after docking any existing head that it waspreviously carrying)—step 900.

Once the processing head 200 has been engaged within the clampingmechanism 202 of the machine tool 100 if needed, the processing head 200is rotated by the machine tool 100 until the processing head 200 ispresented in a known orientation in order that the two manifolds can beconnected—step 902.

Once the processing head 200 is oriented in readiness to receive thesupply-unit 214 the second movement mechanism is operated in order tomove the supply docking-manifold 300 away from the docking surface400—step 904.

Thereafter, the first movement mechanism is operated in order to lowerthe supply-unit 214—step 906.

Once the supply-unit is in the correct vertical height, the secondmovement mechanism is operated again to bring the supplydocking-manifold on the supply-unit 214 into engagement with theprocessing-head docking-manifold—step 908.

As the two manifolds engage the planar surfaces thereof and the locatingmechanisms 314, 316 ensure that the supply-unit 214 is correctlyoriented with respect to the processing head. The skilled person willappreciate that the correct alignment of the supply-unit 214 relative tothe processing head 200 helps to ensure alignment of the componentswhich transmit the energy source (eg the laser beam). In this case thereflectors 208, 222 relative to one another helps to ensure that thelaser beam is correctly focused.

Embodiments of the invention may find a number of applications and inparticular embodiments will typically allow an energy source andassociated media to be connected to a machine-tool 100 to allow themachine-tool 100 to process a work-piece 106 with the energy-source.

One particular application is that of laser-deposition (also known aslaser cladding). Laser deposition may find utility in repairing parts,including turbine blades, pump-impellers, or the like, which have becomedamaged. The laser deposition processes allow material to be added tothe part which can subsequently be machined to finalise the repair ofthe part.

FIG. 10 shows a turbine-blade that has been repaired in which freshmaterial has been added to a tip region 1000 highlighted by the dottedline by this approach.

In other embodiments, the processing head may be utilised to provideother processes which include any of the following: welding; deposition(including additive manufacturing, 3D printing, and directed energydeposition); thermal spraying (in some cases utilising a divergent beamof energy); cladding; cutting; in process thermal management; heattreatment; energy (ie laser) machining; or the like.

FIG. 11 is a schematic illustration of an embodiment of a further aspectof the invention in which a media reservoir is provided in theprocessing head. As described before the processing head 1100 isprovided in a clamping mechanism 1102 attached to a spindle 1104 whichis part of the machine tool 1106. The processing head comprises a mediareservoir 1108 located in the processing head together with an energysource 1110.

Energy from the energy source is applied to the media in the mediareservoir 1108. The media is then transferred along a passage 1112 to anapplication point 1114 where the media is applied to the workpiece.Movement of the processing head and location of the application point1114 is controlled primarily by the machine tool or by the controller asbefore. Additional motion such as rotation or fine positioning istypically incorporated into the processing head. The energy source 1110comprises a heat source and is connected to an electrical supply in themachine tool through the spindle 1104 or via one or more docking systemsas in the embodiment of the invention as illustrated in FIG. 2. Themedia reservoir comprises a chamber arranged to contain a supply ofmedia such as a filament of polymer. The chamber can be refilled withadditional media material while the processing head is in use via adocking system as in the embodiment of FIG. 2 or alternatively whenlocated in a tool changer.

FIG. 12 is an illustrative embodiment of an alternative processing headcomprising two media supplies. For ease only the processing head 1100 isshown in FIG. 12. In this embodiment the processing head comprises anenergy source 1110 together with a first media supply 1116 and a secondmedia supply 1118, each connected to respective passages 1120 and 1122leading to respective first and second application points 1124 and 1126.The first media supply can comprise a building material and the secondmedia supply can comprise a support material or the first and secondmedia may comprise different colours or alternative media that are usedto construct a more complex work piece. The first media can be one of abuild material or a support media. The controller or the machine toolcan control application of the media by positioning of the processinghead and control of deposition of the media. Additionally, finepositioning can be incorporated into the processing head such asextension or retraction of the application points to favour one or theother. The media reservoirs 1116 and 1118 can be replenished when theprocessing head is in use via a media supply while in an operativeposition or while the processing head is off cycle in the tool changer.The energy source can be a battery powered energy source and can also berecharged while the processing head is in the tool changer.

Turning now to FIG. 13, which shows a material processing head arrangedto extrude heated polymer with power and media supplied external to theprocessing head, perhaps through a manifold as described above. In thisembodiment the processing head 1150 comprises a clamping mechanism 1152and a first deposition head 1154 and a second deposition head 1156. Theclamping mechanism, which is sometimes referred to as a tool holder, maybe an ISO 40 taper or HSK 63a.

The processing head is one example representing “material extrusion”devices as defined by the ASTM F2792 standard. Thus, the depositionheads 1154 and 1156 are arranged to extrude material to a work piece.The processing head also comprises a first and a second media supply1158 and 1160. In this embodiment the media supply comprises a firstchannel and a second channel 1162 and 1164 each arranged to guide afirst and a second filament of polymer forming the media providing themedia supplies 1158, 1160. A media is supplied to the first and secondchannels from a media supply mechanism. The media supply mechanism isarranged to connect to a manifold. A power supply is also provided tothe processing head from the manifold, similar mutatis mutandis to themanifold described in earlier figures. A filament feeding mechanism 1166is located in the processing head and feeds the first and secondfilament to respective first 1168 and second 1170 heated chambers. Thepower supply (typically connected via a manifold and the connection isshown here at 1172) supplies energy to first and second heating chambersand within the respective chambers the first and second filaments areheated and a semi liquid media is supplied to the first 1154 and seconddeposition head 1156.

An alternative embodiment is shown in FIG. 14 where the head is designedfor material jetting as acknowledged by the ASTM F2792 standard. Thus,the head of FIG. 14 may be similar to an inkjet, an aerosol jet, or thelike. In this embodiment a first 1200 and a second 1202 liquid media isprovided in the processing head. In this embodiment each deposition head1204 and 1206 each comprise a number of liquid jets arranged to depositliquid droplets on, or at least toward, the work piece. The media may beliquid or may be selected from other jettable fluids such as liquidsfilled with suspended particles as is known in the art. A first 1208 anda second 1210 media chamber are each provided in the processing head anda supply of media is in each chamber. The media may optionally betemperature controlled, especially where maintaining a jettableviscosity is critical. A controller is provided to control deposition ofthe media from the processing head onto the work piece. The controllerin this embodiment includes a pressure management valve 1212. An energysource is provided and comprises a battery 1214, or a similar mechanismto generating power. The battery 1214 provides energy for controllingapplication of the media to the work piece and can also provide energyin the form of heat to the media. Each first and second chamber is alsoconnected to a first and a second duct 1216, 1218 which allow the mediawithin the media chambers 1208, 1210 to be replenished. The first andsecond ducts are connectable to a material feed or manifold in the toolchanger. Other embodiments may not be replenishable in this manner.

The manifold can be connected to the processing head while the head isclamped to the machine tool. The battery can also be connected to amains electricity supply through the manifold (ie through a connection1219) and the battery can be recharged while the manifold is connectedto the processing head.

Also indicated in FIG. 14 is a control board 1220 provided to controlmovement of the processing head, jetting pulses and to control pressurein the media chambers 1208 and 1210.

A wireless communication mechanism for connecting to a data source fordata for printing an image and for controlling and coordinating theposition of the head by mechanism of the CNC position controller is alsoprovided. Such wireless communication mechanisms are conventional andare not described further. Alternatively, data may be supplied to thedevice via a wired connection presented to the head from the manifold ordocking system, by including a stored memory device into the processinghead such as a memory card or by more conventional mechanisms.

Another embodiment of the invention is illustrated in FIG. 15 whichshows an embodiment arranged to extrude heated polymer. In thisembodiment as in the embodiment of FIG. 13 the media is provided in theform of a polymer filament. The same reference numerals are used forcorresponding elements. In this embodiment first and second filaments1158 and 1160 are each provided as a filament wound on first and secondspools 1300 and 1302. First and second filaments are moved from therespective first and second spools 1300 and 1302 by respective filamentfeeding mechanisms 1166. An energy source (not shown) provides energy tothe first and second chambers to heat the filaments as they pass throughthe first and second chambers 1168 and 1170. A power supply 1304 isconnected to the processing head through a manifold connectable to theprocessing head. In this embodiment the entire processing head can beautomatically changed when the media is used up. In this way processingis not delayed and the head with the depleted spools can be replenishedwhile the processing head is out of use and located in the tool changeror other storage location.

FIG. 16 shows a further embodiment having a processing head 200 arrangedto selectively be held in a clamping mechanism 202. This embodiment isperhaps similar to the embodiment shown in FIGS. 2 though 4 and likeparts are referred to with like reference numerals.

In the embodiment being described in relation to FIG. 16 the energysource is provided by a high-voltage electrical supply 516 and theguiding mechanism arranged to direct the energy source to the work-piece104 is provided by a conductive path 520 and electrode 508. Typically,the conductive path 520 may be provided by a wire, such as a copperwire, cable, or the like.

A media supply 224 is also provided and arranged to supply a fluid,which may be any one or more of the other fluids described herein, tothe work-piece 104.

For convenience and protection, the conductive path 520 and media supply224 are contained within a flexible supply unit 514.

In the embodiment of FIG. 16, it will be seen that work-piece isconnected to earth 1600 and thereby it is possible to strike an arc 513with the work-piece to provide a plasma based energy source.

As with the earlier embodiment, a supply docking manifold 600 isprovided and here is provided on an end region of the flexible supplyunit 514 and arranged to be connected to a processing-head manifold 1602on the processing head 200.

A substantially planar docking surface 700 may be provided against whichthe supply docking manifold 600 may be stored when not in use. Here theplanar surface is shown on the electrical supply 516.

FIGS. 17 a to 17 b show the embodiment of FIG. 16 in various stages ofassembly.

Thus, it can be seen from FIG. 17 a that the processing head 200 is keptin a tool station, or the like, remote from the clamping mechanism 202when it is not being used. In this state, the clamping mechanism is freeto hold other processing heads or machining heads to perform processeson the work-piece 104 that the processing head 200 cannot perform. Itcan be seen that the supply docking manifold 600 is placed on thesubstantially planar docking surface 700.

A mechanism, such as a robot arm, tool changing mechanism or the like(not shown) is then used to move the processing head 200 into theclamping mechanism 202. This arrangement of the components is shown inFIG. 17 b and as such, the robot arm may be thought of as being amechanism arranged to move the supply docking-manifold; ie a movementmechanism.

Further a movement mechanism (which may or may not be the same movementmechanism used to move the processing head), such as a robotic arm orthe like (not shown), is then used to move the flexible supply unit 514,including the guiding mechanism 520, and the supply docking manifold 600into place such that the supply docking manifold 600 is connected to theprocessing-head docking manifold 1602. This arrangement of components isshown in FIG. 17 c and allows fluids to be passed down the media supply224 through the supply docking manifold 600, through the processing-headdocking manifold 1602 and into the processing head 200. Further, theconnection of the guiding mechanism 520 allows electricity to be passedfrom the electrical supply 516, to the processing head 200, through theelectrode 508, across a gap to the work-piece 104 and finally on toground 1600.

FIG. 18 shows a further example embodiment in which a processing head isarranged to provide a source of energy which is directed on to a workpiece adjacent the processing head.

The Figure is similar to FIG. 2 and like parts are referred to with likereference numerals. However, in the embodiment being described inrelation to FIG. 18 the processing head does not supply media and issimply arranged to supply energy to the work piece. The dockingmechanism may function in a similar manner to that described in relationto FIGS. 3, 4 a, 4 b and 4 c or in FIGS. 16 a, 16 b, 16 c and 17,mutatis mutandis and will not be described again. The skilled personwill note that the 304, 306, 308 and 310 may well be omitted in anembodiment that supplies energy, without media to the work piece.However, it is conceivable that such embodiments will supply fluids suchas coolants, shielding gases and the like. Such fluids might be passedthrough ducts in the manifold as shown in FIG. 3. In yet furtheralternative embodiments, fluids may be delivered directly onto the workpiece and not via the manifold and subsequently processed via theprocessing head.

It will be noted that, in FIG. 18, the media supply has been removed.

Thus, in the embodiment of FIG. 18, the controller 106 is arranged tocontrol the movement of the laser beam 206 to move across the work piece104. The speed at which the controller moves the laser beam 206 acrossthe work piece will affect the power delivered to a given area (ieportion) of the work piece. In addition, the controller 106 is arrangedto turn the laser on and/off to control the power.

It will be appreciated that the skilled man may vary the combination offeatures that are provided in a particular embodiment of a processinghead. For example fewer or more deposition points could be included inthe same head. Additionally treatment energy sources could beincorporated into the heads such as UV, IR, photonic light sources orthe like in order to cure or fuse the media being deposited as is knownin the art.

1. An apparatus comprising: a processing head configured to betemporarily held by a clamp of a machine tool, the processing head alsoconfigured to deposit one or more media onto a workpiece; wherein theprocessing head comprises: a guide configured to direct energy from anenergy source onto at least one of: the workpiece or the one or moremedia; and one or more supplies configured to store and provide the oneor more media.
 2. The apparatus of claim 1, wherein the one or moresupplies comprise one or more reservoirs within the processing head. 3.The apparatus of claim 1, wherein the one or more supplies comprise oneor more replaceable cartridges.
 4. The apparatus of claim 1, wherein theone or more supplies comprise one or more chambers within the processinghead.
 5. The apparatus of claim 1, wherein the processing head furthercomprises: at least one manifold configured to deliver the one or moremedia to the one or more supplies while the processing head is connectedto a spindle of the machine tool.
 6. The apparatus of claim 1, whereinthe processing head further comprises: a first docking manifoldconfigured to be temporarily connected to a second docking manifold ofthe machine tool, the first docking manifold configured to receive theenergy from the energy source through the second docking manifold. 7.The apparatus of claim 1, wherein the energy source is located withinthe processing head.
 8. A system comprising: a machine tool comprising aclamp; and a processing head configured to be temporarily held by theclamp of the machine tool, the processing head also configured todeposit one or more media onto a workpiece; wherein the processing headcomprises: a guide configured to direct energy from an energy sourceonto at least one of: the workpiece or the one or more media; and one ormore supplies configured to store and provide the one or more media. 9.The system of claim 8, wherein: the system comprises multiple processingheads; and the clamp is configured to temporarily receive each of theprocessing heads at different times.
 10. The system of claim 8, whereinthe processing head is configured to focus the energy from the energysource in line with a longitudinal axis of the processing head.
 11. Thesystem of claim 8, wherein the guide comprises at least one of: a lens,a mirror, a prism, a diffraction grating, a beam expander, a spatiallight modulator, an optic, an electrical coupling mechanism, aconductive media path, an induction coupling mechanism, a shieldedchannel, a beam steering component, a beam steering field generator, amicro-electromechanical system, or a micro-mirror device.
 12. The systemof claim 8, wherein the one or more supplies comprise at least one of:one or more reservoirs within the processing head; one or morereplaceable cartridges; or one or more chambers within the processinghead.
 13. The system of claim 8, wherein the processing head furthercomprises: at least one manifold configured to deliver the one or moremedia to the one or more supplies while the processing head is connectedto a spindle of the machine tool.
 14. The system of claim 8, wherein:the processing head further comprises a first docking manifold; themachine tool further comprises a second docking manifold; and the firstdocking manifold is configured to be temporarily connected to the seconddocking manifold and to receive the energy from the energy sourcethrough the second docking manifold.
 15. The system of claim 8, whereinthe energy source is located within the processing head.
 16. The systemof claim 15, wherein the energy source is configured to provide at leastone of: electricity, pressurized gas, pressurized vapor, storedmechanical energy, stored chemical energy, plasma, or electromagneticenergy.
 17. The system of claim 8, further comprising: a machining headconfigured to remove material from the workpiece; wherein the clamp isfurther configured to temporarily receive the machining head.
 18. Thesystem of claim 17, wherein the machine tool is configured to: move afirst of the heads from an operable position to a head changingposition; release the first head from the clamp; select a second of theheads; receive the second head in the clamp; and return the second headto the operable position.
 19. The system of claim 8, wherein the machinetool comprises a multi-axis computer numerically controlled (CNC)machine.
 20. The system of claim 9, further comprising a controllerconfigured to select the processing head to be received by the clamp andto control at least one of movement, position, or action of theprocessing head received by the clamp.
 21. The system of claim 8,wherein the guide is configured to direct at least one of: a laser beam,an electron beam, an arc, plasma, focused electromagnetic radiation, ordivergent electromagnetic radiation.
 22. The system of claim 8, whereinthe one or more supplies are configured to store at least one of: ametal, a polymer, a ceramic material, a cooling fluid, a processingfluid, or a gas.
 23. The system of claim 8, wherein the processing headis configured such that the energy from the energy source melts the oneor more media within the processing head.
 24. The system of claim 8,wherein the processing head is configured such that the energy from theenergy source melts the one or more media on the workpiece.
 25. A methodcomprising: causing a machine tool to select a processing head from astorage location and temporarily insert the processing head into a clampof the machine tool, the processing head comprising: a guide configuredto direct energy from an energy source onto at least one of: theworkpiece or the one or more media; and one or more supplies configuredto store and provide the one or more media; and operating the processinghead to deposit the one or more media onto the workpiece and to directthe energy from the energy source onto at least one of: the workpiece orthe one or more media.
 26. The method of claim 25, further comprising:causing the machine tool to select a second processing head from thestorage location and temporarily insert the second processing head intothe clamp of the machine tool; and operating the second processing headto deposit one or more additional media onto the workpiece.
 27. Themethod of claim 25, further comprising: causing the machine tool toselect a machining head from the storage location and temporarily insertthe machining head into the clamp of the machine tool; and removingmaterial from the workpiece using the machining head.